DEVICE MODULE AND METHOD OF MANUFACTURING THE SAME

Abstract

 The invention provides a device module that can be manufactured without inserting a part of an external connection into a housing recess of a die. A method of manufacturing the device module is also provided. The device module includes a base 100, a plastic part 200 provided on the base 100, a touch sensor 300 provided on the base 100 and embedded in the plastic part 200, and an external connection 400. The external connection 400 includes an embedded portion 410 and a lead-out portion 420. The embedded portion 410 is connected to the touch sensor 300, extends along the base 100, and is embedded in the plastic part 200. The lead-out portion 420 is contiguous with the embedded portion 410 and led out of the plastic part 200.

Description

[0001] The invention relates to device modules and methods of manufacturing the device modules.

[0002] Japanese Unexamined Patent Publication No. 2011-126236 discloses a device module including a film, a plastic part provided on the film, a functional device embedded in the plastic part, and a transmission cable. The transmission cable has a first portion and a second portion excluding the first portion. The first portion is connected to the functional device and embedded in the plastic part together with the functional device. The second portion protrudes from the plastic part in the thickness direction of the plastic part.

[0003] When the plastic part is molded on the film using a die, the second portion of the transmission cable is placed in a housing recess of a die. The housing recess communicates with a cavity of the dies. To prevent the ingress of plastic material into the housing recess, the shape of the housing recess should conform to the outer shape of the second portion of the transmission cable. This makes it very difficult to insert the second portion of the transmission cable into the housing recess of the die.

[0004] In view of the above circumstances, the invention provides a device module that can be manufactured without inserting a part of an external connection into a housing recess of the die. The invention also provides a method of manufacturing the device module.

[0005] A device module according to the invention includes a base, a plastic part, and an external connection. The plastic part is provided on the base. The device is provided on the base and embedded in the plastic part. The device is a sensor, an electronic device, or a circuit board. The external connection includes an embedded portion and a lead-out portion. The embedded portion is connected to the device, extends along the base, and is embedded in the plastic part. The lead-out portion is contiguous with the embedded portion and led out of the plastic part.

[0006] In the device module in accordance with this aspect, the embedded portion of the external connection is embedded in the plastic part and extends along the base. The lead-out portion of the external connection is contiguous with the embedded portion and led out of the plastic part. This arrangement makes it possible to embed the plastic part (mold plastic material) placing the base, the device, and the embedded portion of the external connection into a cavity of first and second dies and holding the lead-out portion of the external connection between the first and second dies or between the first die and the base. Therefore, it is possible to manufacture the device module without inserting the lead-out portion of the external connection into a housing recess of a die, unlike the conventional device module described above. Moreover, the embedded portion of the external connection is located on the base, and the lead-out portion of the external connection is held between the first and second dies or between the first die and the base. This arrangement reduces the possibility of movement of the external connection if pressed by the plastic material injected into the cavity.

[0007] The base may include a base body and an affixed portion. The base body may be fixed to the plastic part. The affixed portion may be contiguous with the base body and not fixed to the plastic part. The lead-out portion may be affixed to and extends along the affixed portion.

[0008] In the device module in accordance with this aspect, the affixed portion and the lead-out portion affixed thereto are held in a collective manner between the first and second dies when molding the plastic part. Therefore, the lead-out portion is protected by the affixed portion against one of the first and second dies.

[0009] The plastic part may include a plastic body and a protruding portion contiguous with the plastic body. The plastic body may be affixed to the base. The lead-out portion may include a fixed portion and a free portion contiguous with the fixed portion. The fixed portion may be affixed to and extending along the protruding portion.

[0010] The device module may further include a protecting part configured to partially cover the lead-out portion. In the device module in accordance with this aspect, the lead-out portion is protected by the protecting part.

[0011] The protecting part may be continuously connected or affixed to the plastic part. This aspect of the invention can improve the tensile strength of the lead-out portion.

[0012] The lead-out portion may be partially affixed to an outer face of the plastic part. The base may have at least one of a film or a plastic material.

[0013] The sensor may be a film sensor. The external connection may be of film shape to be provided integrally with the sensor.

[0014] A first method of manufacturing a device module according to the invention includes preparing a device, an external connection, and a base, the device being a sensor, an electronic device, or a circuit board, the external connection including a lead-out portion and an embedded portion, and the embedded portion being connected to the device; affixing the device and the embedded portion of the external connection onto the base; followed by placing the base, the device, and the embedded portion of the external connection in a cavity of first and second dies, and holding the lead-out portion of the external connection between the first and second dies or between the first die and the base; and in this state, injecting a plastic material onto the base in the cavity to insert-mold the device and the embedded portion of the external connection in the plastic material.

[0015] According to the first method, the embedded portion of the external connection as fixed to the base is placed in the cavity, and the lead-out portion of the external connection is held between the first and second dies or between the first die and the base. This method makes it possible to manufacture the device module without inserting the lead-out portion of the external connection into a housing recess of a die. Moreover, the embedded portion is fixed to the base, and the lead-out portion is held between the first and second dies or between the first die and the base. It is therefore possible to reduce the possibility of movement of the external connection if pressed by the plastic material injected into the cavity.

[0016] The affixing of the embedded portion may include affixing the embedded portion in such a manner as to extend from the device on the base to an end of the base. According to the first method of this aspect, by fixing the embedded portion so as to extend from the device on the base to the end of the base, the lead-out portion protrudes from the end of the base. Accordingly, the method makes it easy to hold the lead-out portion between the first and second dies or between the first die and the base.

[0017] The base may include a base body and an affixed portion. The affixed portion may be contiguous with the base body. The affixing onto the base may include affixing the device and the embedded portion of the external connection onto the base body of the base and affixing the lead-out portion of the external connection onto the affixed portion of the base. The placing in the cavity may include placing the base body of the base, the device, and the embedded portion of the external connection in the cavity. The holding between the first and second dies may include holding the lead-out portion of the external connection and the affixed portion of the base between the first and second dies. The injection of the plastic material may include injecting the plastic material onto the base body of the base and thereby insert molding the device and the embedded portion of the external connection in the plastic material. According to the first method of this aspect, as the lead-out portion and the affixed portion are held between the first and second dies, the affixed portion protects the lead-out portion against one of the first and second dies.

[0018] The lead-out portion may include a fixed portion contiguous with the embedded portion and a free portion contiguous with the fixed portion. The placing in the cavity may include disposing the fixed portion of the lead-out portion along a wall of the cavity. The holding between the first and second dies may include holding the free portion of the lead-out portion between the first and second dies. The injection of the plastic material may include injecting the plastic material onto the base in the cavity to insert-mold the device, the embedded portion of the external connection, and the fixed portion of the lead-out portion of the external connection in the plastic material.

[0019] According to the first method of this aspect, a part (the fixed portion) of the external connection can be fixed not to the portion of the plastic part on the base but to another portion of the plastic part. Therefore, the method provides a higher degree of flexibility in design.

[0020] The lead-out portion may include a fixed portion contiguous with the embedded portion and a free portion contiguous with the fixed portion. The placing in the cavity may include disposing the fixed portion of the lead-out portion in mid-air in the cavity. The holding between the first and second dies may include holding the free portion of the lead-out portion between the first and second dies. The injection of the plastic material may include injecting the plastic material onto the base in the cavity to insert-mold the device, the embedded portion of the external connection, and the fixed portion of the lead-out portion of the external connection in the plastic material.

[0021] According to the first method of this aspect, the fixed portion of the lead-out portion can be disposed in mid-air in the cavity when insert-molded in the plastic material. That is, a part (the fixed portion) of the external connection can be embedded not in the portion of the plastic part on the base but in another portion of the plastic part. Therefore, the method provides a higher degree of flexibility in design.

[0022] The holding of the lead-out portion of the external connection between the first and second dies may include holding the lead-out portion also between the first die and the base.

[0023] A second method of manufacturing a device module according to the invention includes preparing an external connection, a device, a protecting part, and a base, the external connection including an embedded portion and a lead-out portion, and the device being a sensor, an electronic device, or a circuit board and connected to the embedded portion, and the protecting part partially covering the lead-out portion; affixing the device and the embedded portion of the external connection onto the base; placing the base, the device, and the embedded portion of the external connection into a cavity of the first and second dies, and holding the protecting part between the first and second dies or between the first die and the base; and in this state, injecting a plastic material onto the base in the cavity to insert-mold the device and the embedded portion of the external connection in the plastic material.

[0024] According to this second method, the embedded portion of the external connection as fixed to the base is placed in the cavity. Also, the protecting part, which partially covers the lead-out portion of the external connection, is held between the first and second dies or between the first die and the base. This method makes it possible to manufacture the device module without inserting the lead-out portion of the external connection into a housing recess of a die. Moreover, the embedded portion is fixed to the base, and the protecting part with the lead-out portion passing therethrough is held between the first and second dies or between the first die and the base. It is therefore possible to reduce the possibility of movement of the external connection if pressed by the plastic material injected into the cavity. Further, as the protecting part is held between the first and second dies or between the first die and the base, the protecting part protects the lead-out portion against the first and second dies or against the first die and the base.

[0025] The holding of the protecting part may include disposing a part of the protecting part in the cavity. The injection of the plastic material may include affixing the part of the protecting part to the plastic material injected in the cavity. The second device method of this aspect makes it easy to affix the protecting part to the plastic part.

[0026] The invention will now be described by way of example only and without limitation by reference to the drawings, in which:

Fig. 1 is a schematic sectional view of a device module in accordance with the First Embodiment of the invention;

Fig. 2 is a view illustrating a manufacturing process of the device module.

Fig. 3 is a schematic sectional view of a device module in accordance with the Second Embodiment of the invention;

Fig. 4 is a view illustrating a manufacturing process of the device module.

Fig. 5 is a schematic sectional view of a device module in accordance with the Third Embodiment of the invention;

Fig. 6 is a view illustrating a manufacturing process of the device module;

Fig. 7 is a schematic sectional view of a device module in accordance with the Fourth Embodiment of the invention;

Fig. 8 is a view illustrating a manufacturing process of the device module;

Fig. 9 is a schematic sectional view of a device module in accordance with the Fifth Embodiment of the invention;

Fig. 10 is a view illustrating a manufacturing process of the device module;

Fig. 11 is a schematic sectional view of a device module in accordance with the Sixth Embodiment of the invention;

Fig. 12 is a view illustrating a manufacturing process of the device module.

Fig. 13 is a schematic sectional view of a device module in accordance with the Seventh Embodiment of the invention.

Fig. 14 is a view illustrating a manufacturing process of the device module.

Fig. 15 is a schematic sectional view of a device module in accordance with a first example modification of the First Embodiment.

Fig. 16 is a schematic sectional view of a device module in accordance with a second example modification of the First Embodiment.

Fig. 17 is a schematic sectional view of a device module in accordance with a third example modification of the First Embodiment.

Fig. 18 is a schematic sectional view of a device module in accordance with a fourth example modification of the First Embodiment.

Fig. 19 is a schematic sectional view of a device module in accordance with a first example modification of the Third Embodiment;

Fig. 20 is a schematic sectional view of a device module in accordance with a first example modification of the Seventh Embodiment.

Fig. 21 is a schematic sectional view of a device module in accordance with a second example modification of the Seventh Embodiment.

[0027] In the description which follows, relative spatial terms such as "lower", "upward", "downward", "bottom", "left", "horizontal", "vertical", etc., are used for the convenience of the skilled reader and refer to the orientation of the device module and its constituent parts as depicted in the drawings. No limitation is intended by use of these terms, either in use of the invention, during its manufacture, shipment, custody, or sale, or during assembly of its constituent parts or when incorporated into or combined with other apparatus.

[0028] The First to Seventh Embodiments of the invention will be described below.

[0029] First, a device module in accordance with the First Embodiment of the invention will be described with reference to Fig. 1. The device module shown in Fig. 1 is a touch sensing device. The device module includes a base 100, a plastic part 200, a touch sensor 300 (device), and an external connection 400. These constituents of the device module will be described below in detail. In Fig. 1, D1 refers to the thickness direction of the device module and the plastic part 200, and D2 refers to the lengthwise direction of the device module. D1 is orthogonal to D2. The short direction (not shown) of the device module is orthogonal to D1 and D2.

[0030] The base 100 is a generally rectangular flexible film of optically transparent plastic material such as a PET (polyethylene terephthalate) film or an acrylic film. The base 100 has a first face 101 (an inner face) and a second face 102 (an outer face). Ornamental printing is provided on the entire region or a partial region (e.g., a circumferential region, or one end in the lengthwise direction D2 or in the short direction) of the first face 101 of the base 100.

[0031] The plastic part 200 is an insulating member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic part 200 is generally of U-shape in sectional view and provided on the first face 101 of the base 100. As it is formed on the first face 101 of the base 100, the base 100 generally adheres to or is integrated with the plastic part 200 and has hardened (has lost flexibility) generally in a U-shaped curve extending along the plastic part 200. The second face 102 of the base 100 has a flat central area serving as a touch sensing surface of the device module.

[0032] The touch sensor 300 a capacitive touch panel of generally rectangular shape and in rigid or flexible sheet form. The touch sensor 300 can detect a detection object such as a finger that touches the touch sensing surface of the base 100. The touch sensor 300 is fixed to the central area of the first face 101 of the base 100 and embedded in the plastic part 200. The touch sensor 300 extends substantially parallel to the touch sensing surface of the base 100.

[0033] If the touch sensor 300 is in a rigid transparent sheet form, it may have any one of the configurations (1) to (3) indicated below. If the touch sensor 300 is in a flexible transparent sheet form (if it is a film sensor), it may have any one of the configurations (4) to (6) indicated below.

1) The touch sensor 300 includes a first transparent substrate having first and second faces in its thickness direction D1, a plurality of first transparent electrodes provided on the first face of the first transparent substrate, and a plurality of second transparent electrodes provided on the second face of the first transparent substrate.

2) The touch sensor 300 includes a first transparent substrate, a plurality of first transparent electrodes provided on the first transparent substrate, an insulating layer provided on the first transparent substrate so as to cover the first transparent electrodes, and a plurality of second transparent electrodes provided on the insulating layer.

3) The touch sensor 300 includes a first transparent substrate having a first face, a second transparent substrate having a first face opposed to the first face of the first transparent substrate, a plurality of first transparent electrodes provided on the first face of the first transparent substrate, and a plurality of second transparent electrodes provided on the first face of the second transparent substrate.

4) The touch sensor 300 includes a flexible insulating first transparent film having first and second faces in its thickness direction D1, a plurality of first transparent electrodes provided on the first face of the first transparent film, and a plurality of second transparent electrodes provided on the second face of the first transparent film.

5) The touch sensor 300 includes a flexible insulating first transparent film, a plurality of first transparent electrodes provided on the first transparent film, a flexible insulating second transparent film provided on the first transparent film so as to cover the first transparent electrodes, and a plurality of second transparent electrodes provided on the second transparent film.

6) The touch sensor 300 includes a flexible insulating first transparent film having a first face, a flexible insulating second transparent film having a first face opposed to the first face of the first transparent film, a plurality of first transparent electrodes provided on the first face of the first transparent film, and a plurality of second transparent electrodes provided on the first face of the second transparent film.

[0034] The external connection 400 is flexible. Specifically, the external connection 400 is a flexible printed circuit or a flexible and insulating transparent film. The external connection 400 has an embedded portion 410 and a lead-out portion 420. The embedded portion 410 is fixed to the first face 101 of the base 100 and embedded in the plastic part 200. The embedded portion 410 includes a lengthwise first end of the external connection 400. If the external connection 400 is a flexible printed circuit, the first end of the external connection 400 is connected to at least one of the first and second transparent substrates of the touch sensor 300, or to at least one of the first and second transparent films of the touch sensor 300. Such a flexible printed circuit includes a plurality of conductive lines connected to first and second transparent electrodes. If the external connection 400 is a transparent film, the first end of the external connection 400 is integrally connected to at least one of the first and second transparent substrates of the touch sensor 300, or to at least one of the first and second transparent films of the touch sensor 300. Such a transparent film includes a plurality of conductive lines connected to the first and second transparent electrodes. The embedded portion 410 extends along the first face 101 of the base 100, from the touch sensor 300 to an end of the base 100. The lead-out portion 420 is a portion excluding the embedded portion 410 of the external connection 400 and contiguous with the embedded portion 410. The lead-out portion 420 is led out of an end face of the plastic part 200. The lead-out portion 420 has a lengthwise second end of the external connection 400.

[0035] The device module described above may be manufactured using first and second dies 10, 20 as illustrated in Fig. 2. The first die 10 includes a projection 11, a sprue 13, and first and second split faces 13, 14. The projection 11 projects in the thickness direction D1 (downward in Fig. 2) toward the second die 20. The sprue 12 passes through the first die 10 in the thickness direction D1. The first split face 13 is located on one side in the lengthwise direction D2 of the projection 11, and the second split face 14 is located on the other side in the lengthwise direction D2 of the projection 11. The second split face 14 is located further in the other thickness direction D1 (higher in Fig. 2) than the first split face 13 by the thickness of the lead-out portion 420 of the external connection 400.

[0036] The second die 20 has a recess 21 and first and second split faces 22, 23. The recess 21 is adapted to receive the projection 11 and has a dimension in the thickness direction D1 (i.e. depth) larger than the dimension in the thickness direction D1 (i.e. height) of the projection 11. When the first and second dies 10, 20 are closed together, the recess 21 receives the projection 11, and the projection 11 and the recess 21 define a space. This space serves as a cavity of the first and second dies 10, 20. The cavity is of shape conforming to the outer shape of the device module excluding the lead-out portion 420. The first split face 22 is located on the one side in the lengthwise direction D2 of the recess 21, and the second split face 23 is located on the other side of the recess 21 in the lengthwise direction D2. The first and second split faces 22, 23 extend at the same height position. When the first and second dies 10, 20 are closed together, the first split faces 13, 22 are in contact with each other, while a gap G is left between the second split faces 14, 23 corresponding to the thickness of the lead-out portion 420.

[0037] A method of manufacturing the device module using the first and second dies 10, 20 will be described below with reference to Fig. 2. The first step is to prepare the base 100 and the touch sensor 300 with the external connection 400 connected thereto. The touch sensor 300 and the embedded portion 410 of the external connection 400 are affixed to the first face 101 of the base 100 with an adhesive. As a result, the embedded portion 410 extends along the base 100, from the touch sensor 300 to the end of the base 100, and the lead-out portion 420 protrudes from an end of the base 100.

[0038] The next step is to place the base 100, the external connection 400 of the touch sensor 300, and the embedded portion 410 into the recess 21 of the second die 20. This causes the base 100 to curve generally in U-shape in sectional view conforming to the shape of the wall of the recess 21, and the embedded portion 410 is accordingly curved. In addition, the lead-out portion 420 of the external connection 400 is disposed between the second split faces 14, 23 of the first and second dies 10, 20.

[0039] After that, the first and second dies 10, 20 are brought close to each other to be closed together. Then, the projection 11 of the first die 10 is received in the recess 21 of the second die 20. This creates the cavity between the projection 11 and the recess 21. The base 100, the touch sensor 300, and the embedded portion 410 of the external connection 400 are placed in the cavity. At this point, the first split faces 13, 22 of the first and second dies 10, 20 are brought into contact with each other, and the second split faces 14, 23 of the first and second dies 10, 20 holds the lead-out portion 420 of the external connection 400 therebetween.

[0040] After that, plastic material R is injected through the sprue 12 of the first die 10 onto the base 100 in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 410 of the external connection 400 are embedded in the plastic material R on the base 100. The plastic material R hardens to form the plastic part 200. At this point, the base 100 adheres to or becomes integrated with the plastic part 200 and hardens. This is how to insert-mold the touch sensor 300 and the embedded portion 410 of the external connection 400 in the plastic part 200 on the base 100, with the lead-out portion 420 of the external connection 400 led out of an end face of the plastic part 200. Lastly, the first and second dies 10, 20 are separated from each other to take out the completed device module.

[0041] The above described device module has at least the following technical features and advantages. First, the embedded portion 410 of the external connection 400 is embedded in the plastic part 200 and extends along the base 100 from the touch sensor 300 to the end of the base 100. The lead-out portion 420 of the external connection 400 is led out of the end face of the plastic part 200. Therefore, the insert-molding process can be performed placing the base 100, the touch sensor 300, and the embedded portion 410 of the external connection 400 in the cavity of the first and second dies 10, 20 while the first and second dies 10, 20 hold therebetween the lead-out portion 420 of the external connection 400. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 420 of the external connection 400 into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 410 of the external connection 400 are affixed onto the base 100, and the lead-out portion 420 of the external connection 400 is held between the first and second dies 10, 20. This arrangement reduces the possibility of movement of the external connection 400 if pressed by the plastic material R injected into the cavity.

Second Embodiment

[0042] Next, a device module in accordance with the Second Embodiment of the invention will be described with reference to Fig. 3. The device module shown in Fig. 3 has the same configuration as that of the First Embodiment, except for a base 100' of different shape from that of the base 100. This difference will be described below in detail, and overlapping descriptions will be omitted. A symbol _'_ is added to the reference numerals of the base and its subelements in this embodiment to distinguish them from those of the First Embodiment. Fig. 3 also indicates the directions D1 and D2.

[0043] The base 100' is a generally rectangular flexible film of optically transparent plastic material such as a PET (polyethylene terephthalate) film or an acrylic film. The base 100' has first and second faces 101', 102', a base body 110', and an affixed portion 120'. The first face 101' is the inner face of the base 100', and the second face 102' is the outer face of the base 100'. The base body 110' is fixed to the plastic part 200. Ornamental printing is provided on the entire region or a partial region (e.g., a circumferential region, or one end in the lengthwise direction D2 or in the short direction) of the first face 101' of the base body 110'. The affixed portion 120' contiguous with the base body 110' is not fixed to the plastic part 200. That is, the affixed portion 120' extends out of the plastic part 200.

[0044] The plastic part 200 is disposed on the first face 101' of the base body 110'. This causes the base body 110' to generally adhere to or be integrated with the plastic part 200 and hardens (the base body 110' is fixed to the plastic part 200 and has lost flexibility) generally in a U-shaped curve extending along the plastic part 200. The second face 102' of the base 100' has a flat central area serving as a touch sensing surface of the device module.

[0045] The touch sensor 300 is fixed to the central area of the first face 101' of the base body 110' and is embedded in the plastic part 200. The touch sensor 300 extends substantially parallel to the touch sensing surface. Further, the touch sensor 300 is connected to the embedded portion 410 of the external connection 400, and the touch sensor 300 and the embedded portion 410 are affixed to the first face 101' of the base body 110' and embedded in the plastic part 200. The embedded portion 410 extends along the first face 101' of the base body 110', from the touch sensor 300 to the boundary between the base body 110' and the affixed portion 120'. The lead-out portion 420 is fixed to the first face 101' of the affixed portion 120' and is led out of the end face of the plastic part 200. The lead-out portion 420 extends along the first face 101' of the affixed portion 120'.

[0046] The device module may be manufactured using a first die 10' as shown in Fig. 4. The first die 10' has the same configuration as the first die 10, except that the second split face 14' is at a different height from the second split face 14 as detailed below. This difference will be described below in detail, and overlapping descriptions will be omitted. A symbol _'_ is added to the reference numerals of the first die and its subelements of this embodiment to distinguish them from those of the First Embodiment. The second die 20 has the same configuration as that of the First Embodiment. The cavity of the first and second dies 10', 20 is of shape conforming to the outer shape of the device module excluding the lead-out portion 420 and the affixed portion 120'.

[0047] The second split face 14' is located further in the other thickness direction D1 (higher in Fig. 4) than the first split face 13' by the combined thickness of the affixed portion 120' of the base 100' and the lead-out portion 420 of the external connection 400. When the first and second dies 10', 20 are closed together, the first split face 13', 22 are in contact with each other, while a gap G' is left between the second split faces 14', 23 corresponding to the combined thickness of the affixed portion 120' and the lead-out portion 420.

[0048] A method of manufacturing the device module using the first and second dies 10', 20 will be described below with reference to Fig. 4. The first step is to prepare the base 100' and the touch sensor 300 with the external connection 400 connected thereto. The touch sensor 300 and the embedded portion 410 of the external connection 400 are affixed to the first face 101' of the base body 110' of the base 100' with an adhesive, and the lead-out portion 420 of the external connection 400 is affixed to the first face 101' of the affixed portion 120' of the base 100' with an adhesive. As a result, the embedded portion 410 extends along the base body 110', from the touch sensor 300 to the above-mentioned boundary, and the lead-out portion 420 extends along the affixed portion 120'.

[0049] After that, the base body 110' of the base 100', the touch sensor 300, and the embedded portion 410 of the external connection 400 are placed into the recess 21 of the second die 20. This causes the base body 110' to curve generally in U-shape in sectional view conforming to the shape of the wall of the recess 21, and the embedded portion 410 is accordingly curved. In addition, the affixed portion 120' of the base 100' and the lead-out portion 420 of the external connection 400 are disposed between the second split faces 14', 23 of the first and second dies 10', 20.

[0050] After that, the first and second dies 10', 20 are brought close to each other to be closed together. Then, the projection 11' of the first die 10' is inserted into the recess 21 of the second die 20. This generates the cavity between the projection 11' and the recess 21. The base body 110', the touch sensor 300, and the embedded portion 410 of the external connection 400 are placed in the cavity. At this point, the first split face 13', 22 of the first and second dies 10', 20 are brought into contact with each other, and the second split face 14', 23 of the first and second dies 10', 20 hold the affixed portion 120' and the lead-out portion 420 therebetween.

[0051] After that, plastic material R is injected through a sprue 12' of the first die 10' onto the base body 110' in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 410 of the external connection 400 are embedded in the plastic material R on the base body 110'. The plastic material R hardens to form the plastic part 200. At this point, the base body 110' adheres to or becomes integrated with the plastic part 200 and hardens. This is how to insert-mold the touch sensor 300 and the embedded portion 410 of the external connection 400 in the plastic part 200 on the base body 110', with the lead-out portion 420 of the external connection 400 led out of the end face of the plastic part 200. Lastly, the first and second dies 10', 20 are separated from each other to take out the completed device module.

[0052] The above described device module has at least the following technical features and advantages. First, the embedded portion 410 of the external connection 400 is embedded in the plastic part 200 and extends along the base body 110' from the touch sensor 300 to the boundary between the base body 110' and the affixed portion 120'. The lead-out portion 420 of the external connection 400 is affixed to the affixed portion 120' and led out of the end face of the plastic part 200. Therefore, the insert-molding process can be performed placing the base body 110', the touch sensor 300, and the embedded portion 410 of the external connection 400 in the cavity of the first and second dies 10', 20 while the first and second dies 10', 20 hold the affixed portion 120' and the lead-out portion 420 therebetween. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 420 of the external connection 400 into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 410 of the external connection 400 are affixed onto the base body 110', and the lead-out portion 420 of the external connection 400 are held between the first and second dies 10', 20. This arrangement reduces the possibility of movement of the external connection 400 if pressed by the plastic material R injected into the cavity. In addition, the first and second dies 10', 20 hold therebetween the lead-out portion 420 together with the affixed portion 120', so that the affixed portion 120' protects the lead-out portion 420 against the second die 20.

Third Embodiment

[0053] Next, a device module in accordance with the Third Embodiment of the invention will be described with reference to Fig. 5. The device module shown in Fig. 5 has the same configuration as that of the First Embodiment, except for the shape of a base 100", the configuration of a plastic part 200', and the configuration of an external connection 400'. These differences will be described below in detail, and overlapping descriptions will be omitted. A symbol _"_ is added to the reference numerals of the base and its subelements of this embodiment to distinguish them from those of the First Embodiment. A symbol _'_ is added to the reference numerals of the plastic part and the external connection and their subelements of this embodiment to distinguish them from those of the First Embodiment. Fig. 5 also indicates the directions D1 and D2.

[0054] The base 100" is a generally rectangular flexible film of optically transparent plastic material such as a PET (polyethylene terephthalate) film or an acrylic film. It is smaller in the lengthwise direction D2 than the base 100. The base 100" has a first face 101" (an inner face) and a second face 102" (an outer face). Ornamental printing is provided on the entire region or a partial region (e.g., a circumferential region, or one end in the lengthwise direction D2 or in the short direction) of the first face 101" of the base 100".

[0055] The plastic part 200' is an insulating member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic part 200 is generally of U-shape in sectional view. The plastic part 200' includes a plastic body 210' and protruding portions 220', 230'. The plastic body 210' is disposed on the first face 101" of the base 100". This causes the base 100" to generally adhere to or be integrated with the plastic body 210' and harden (have lost flexibility) generally in a U-shaped curve extending along the plastic body 210'. The touch sensor 300 is fixed to the central area of the first face 101" of the base 100" and embedded in the plastic body 210' of the plastic part 200'. The flat central area of the second face 102" of the base 100" serves as the touch sensing surface of the device module. The touch sensor 300 extends substantially parallel to the touch sensing surface. The protruding portions 220', 230' extend contiguously with the respective opposite ends in the lengthwise direction D2 of the plastic body 210', and they curve in the thickness direction D. In other words, the protruding portions 220', 230' of the plastic part 200' do not exist on the first face 101" of the base 100".

[0056] The external connection 400' has the same configuration as the external connection 400, except for the configuration of a lead-out portion 420'. This difference will be described below in detail, and overlapping descriptions will be omitted. The embedded portion 410' of the external connection 400' is affixed onto the first face 101" of the base 100" and embedded in the plastic part 200'. The lead-out portion 420' is a portion excluding the embedded portion 410' of the external connection 400'. The lead-out portion 420' includes a fixed portion 421' contiguous with the embedded portion 410' and a free portion 422' contiguous with the fixed portion 421'. The fixed portion 421' is affixed to and extends along the protruding portion 220' of the plastic part 200'. The free portion 422' protrudes from the end face of the protruding portion 220' of the plastic part 200'.

[0057] The first die 10 used to manufacture the device module may be the same as that of the First Embodiment. The second die 20', as shown in Fig. 6, has the same configuration as that of the second die 20, except that first and second recesses 21a', 21b' are provided in place of the recess 21. This difference will be described below in detail, and overlapping descriptions will be omitted. A symbol _'_ is added to the reference numerals of the second die and its subelements of this embodiment for the distinction from the second die 20 and its subelements of the First Embodiment.

[0058] The first recess 21a' is adapted to receive the projection 11. The second recess 21b' is provided in the bottom of the first recess 21a' and conforms in shape to the base 100". The combined dimension in the thickness direction D1 (combined depth) of the first recess 21a' and the second recess 21b' is larger than the dimension in the thickness direction D1 of the projection 11. When the first die 10, 20' are closed together, the projection 11 is received in the first recess 21a', and the projection 11 and the first and second recesses 21a', 21b' define a space. This space serves as a cavity of the first and second dies 10, 20'. The cavity is of shape conforming to the outer shape of the device module excluding the free portion 422' of the lead-out portion 420'. When the first and second dies 10, 20' are closed together, the first split faces 13, 22' are brought into contact with each other, while a gap G is left between the second split faces 14, 23' corresponding to the thickness of the lead-out portion 420'.

[0059] A method of manufacturing the device module using the first and second dies 10, 20' will be described below with reference to Fig. 6. The first step is to prepare the base 100" and the touch sensor 300 with the external connection 400' connected thereto. The touch sensor 300 and the embedded portion 410' of the external connection 400' are affixed onto the first face 101" of the base 100" with an adhesive. As a result, the embedded portion 410' extends along the base 100", from the touch sensor 300 to the end of the base 100", and the lead-out portion 420" protrudes from the end of the base 100".

[0060] After that, the base 100" is placed into the second recess 21b' of the second die 20', and the touch sensor 300 and the embedded portion 410' of the external connection 400' are placed into the first recess 21 a' of the second die 20'. This causes the base 100" to curve generally U-shape in sectional view conforming to the shape of the wall of the second recess 21b', and the embedded portion 410' is accordingly curved. In addition, the fixed portion 421' of the lead-out portion 420' of the external connection 400' is curved conforming to the shape of the wall of the first recess 21a' (the wall of the cavity) (i.e. disposed along the wall). At this point, the free portion 422' of the lead-out portion 420' is disposed between the second split faces 14, 23' of the first and second dies 10, 20'.

[0061] After that, the first and second dies 10, 20' are brought close to each other to be closed together. Then, the projection 11 of the first die 10 is inserted into the first recess 21 a' of the second die 20'. This creates the cavity between the projection 11 and the first and second recesses 21a', 21b'. The base 100", the touch sensor 300, the embedded portion 410' of the external connection 400', and the fixed portion 421' of the lead-out portion 420' of the external connection 400' are placed in the cavity. At this point, the first split faces 13, 22' of the first and second dies 10, 20' are brought into contact with each other, and the second split faces 14, 23' of the first and second dies 10, 20' hold the free portion 422' of the lead-out portion 420' therebetween.

[0062] After that, plastic material R is injected through the sprue 12 of the first die 10 onto the base 100" in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 410' of the external connection 400' are embedded in the plastic material R on the base 100". In addition, the fixed portion 421' of the lead-out portion 420' of the external connection 400' comes into intimate contact with the plastic material R. The plastic material R hardens to form the plastic part 200. At this point, the base 100" adheres to or becomes integrated with the plastic part 200' and hardens, and the fixed portion 421' of the external connection 400' is fixed to the plastic part 200'. The portion of the plastic part 200' fixed to the base 100" forms the plastic body 210' of the plastic part 200'. The portion of the plastic part 200' fixed to the fixed portion 421' forms the protruding portion 220' of the plastic part 200'. The remaining portion of the plastic part 200' is the protruding portion 230'. This is how to insert-mold the touch sensor 300 and the embedded portion 410' of the external connection 400' in the plastic body 210' of the plastic part 200' on the base 100", affix the fixed portion 421' of the lead-out portion 420' of the external connection 400' to the protruding portion 220', and lead the free portion 422' out of the end face of the protruding portion 220'. Lastly, the first and second dies 10, 20' are separated from each other to take out the completed device module.

[0063] The above described device module has at least the following technical features and advantages. First, the embedded portion 410' of the external connection 400' is embedded in the plastic part 200' and extends along the base 100" from the touch sensor 300 to the end of the base 100". The fixed portion 421' of the lead-out portion 420' of the external connection 400' is affixed to and extends along the protruding portion 220' of the plastic part 200'. The free portion 422' of the lead-out portion 420' of the external connection 400' is led out of the end face of the protruding portion 220'. Therefore, the insert-molding process can be performed placing the base 100", the touch sensor 300 and the embedded portion 410' in the cavity of the first and second dies 10, 20', placing the fixed portion 421' along the wall of the cavity (the wall of the first recess 21a' of the second die 20'), and holding the free portion 422' of the lead-out portion 420' between the first and second dies 10, 20'. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 420' of the external connection 400' into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 410' of the external connection 400' are affixed onto the base 100", and the fixed portion 421' is disposed along the wall of the cavity. The free portion 422' is held between the first and second dies 10, 20'. This arrangement reduces the possibility of movement of the external connection 400 if the embedded portion 410' of the external connection 400' is pressed by the plastic material R injected into the cavity.

Fourth Embodiment

[0064] Next, a device module in accordance with the Fourth Embodiment of the invention will be described with reference to Fig. 7. The device module shown in Fig. 7 is a touch sensing device. This device module includes a base 500, a plastic part 600, a touch sensor 300 (device), and an external connection 700. These constituents of the device module will be described below in detail. In Fig. 7, D1 refers to the thickness direction of the device module and the plastic part 600, and D2 refers to the lengthwise direction of the device module. D1 is orthogonal to D2. The short direction (not shown) of the device module is orthogonal to D1 and D2.

[0065] The base 500 includes a film 510 and a plastic block 520. The film 510 is a generally rectangular flexible film of optically transparent plastic material such as a PET (polyethylene terephthalate) film or an acrylic film. The film 510 has a first face 511 (an inner face) and a second face 512 (an outer face). Ornamental printing is provided on the entire region or a partial region (e.g., a circumferential region, or one end in the lengthwise direction D2 or in the short direction) of the first face 511 of the film 510.

[0066] The plastic block 520 is an insulating and translucent member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic block 520 is generally of U-shape in sectional view and provided on the first face 511 of the film 510. As it is formed on the first face 511 of the film 510, the film 510 generally adheres to or is integrated with the plastic block 520 and has hardened (has lost flexibility) generally in a U-shaped curve extending along the plastic block 520. The second face 512 of the film 510 has a flat central area serving as a touch sensing surface of the device module. The plastic block 520 has a first face 521 and a second face 522 opposed to each other and end faces 523, 524. The second face 522 is affixed to the film 510. The touch sensor 300 is affixed to the center area of the first face 521 and is embedded in a plastic body 610 (to be described) of the plastic part 600. The touch sensor 300 extends substantially parallel to the touch sensing surface of the base 500. The end faces 523, 524 face upward (as shown in Fig. 7).

[0067] The plastic part 600 is an insulating member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic part 600 is generally of U-shape in sectional view and includes the plastic body 610 and protruding portions 620, 630. The plastic body 610 of the plastic part 600 is provided on the first face 521 of the plastic block 520. The protruding portions 620, 630 are contiguous with the respective opposite ends in the lengthwise direction D2 of the plastic body 610 and extend in the thickness direction D1 (extend upward). In other words, the protruding portions 620, 630 do not exist on the first face 521 of the plastic block 520 of the plastic part 600.

[0068] The external connection 700 is flexible. Specifically, the external connection 700 is a flexible printed board or a flexible and insulating transparent film. The external connection 700 includes an embedded portion 710 and a lead-out portion 720. The embedded portion 710 of the external connection 700 is fixed onto the first face 521 of the plastic block 520 and embedded in the plastic body 610 of the plastic part 600, and it includes a lengthwise first end of the external connection 700. The first end of the external connection 700 is connected to the touch sensor 300 in a similar manner to the first end of the external connection 400 of the First Embodiment. The embedded portion 710 extends along the first face 521 of the plastic block 520, from the touch sensor 300 to the end face 523 of the plastic block 520.

[0069] The lead-out portion 720 is a portion excluding the embedded portion 710 of the external connection 700. The lead-out portion 720 has a fixed portion 721 and a free portion 722. The fixed portion 721 is contiguous with the embedded portion 710 and led out of the plastic body 610 of the plastic part 600. The fixed portion 721 is affixed to the outer face of the protruding portion 620 of the plastic part 600 and extends along the protruding portion 620. The free portion 722 is contiguous with the fixed portion 721. The free portion 722 includes a lengthwise second end of the external connection 700.

[0070] The device module described above may be manufactured using first and second dies 30, 40 as illustrated in Fig. 8. The first die 30 includes a projection 31, a sprue 32, first and second split faces 33, 34, and first and second recesses 35, 36. The projection 31 projects in the thickness direction D1 (downward in Fig. 8) toward the second die 40. The sprue 32 passes through the first die 30 in the thickness direction D1. The first split face 33 is located on one side in the lengthwise direction D2 of the projection 31, and the second split face 34 is located on the other side in the lengthwise direction D2 of the projection 31. The second split face 34 is located further in the other thickness direction D1 (higher in Fig. 8) than the first split face 33 by the thickness of the lead-out portion 720 of the external connection 700. The first recess 35 is provided between the projection 31 and the first split face 33, and The second recess 36 is provided between the projection 31 and the second split face 34. The first and second recesses 35, 36 extend in the other thickness direction D1 (upward in Fig. 8).

[0071] The second die 40 includes a recess 41 and first and second split faces 42, 43. The recess 41 is adapted to receive the projection 31 and has a dimension in the thickness direction D1 (i.e. depth) larger than the dimension in the thickness direction D1 (i.e. height) of the projection 31. When the first and second dies 30, 40 are combined with each other (closed together), the recess 41 receives the projection 31. Also, the first and second recesses 35, 36 communicate with the recess 41, and the projection 31, the first and second recesses 35, 36 and the recess 41 define a space. This space serves as a cavity of the first and second dies 30, 40. The cavity is of shape conforming to the outer shape of the device module excluding the lead-out portion 720. The first split face 42 is located on the one side in the lengthwise direction D2 of the recess 41, and the second split face 43 is located on the other side in the lengthwise direction D2 of the recess 41. The first and second split faces 42, 43 extend at the same height position. When the first and second dies 30, 40 are closed together, the first split faces 33, 42 are in contact with each other, while a gap G is left between the second split faces 34, 43 corresponding to the thickness of the lead-out portion 720.

[0072] The base 500 may be manufactured in the following method using dies (not shown). First, the film 510 is placed in a cavity of the dies. After that, plastic material is injected onto the film 510 in the cavity. The plastic material hardens to form the plastic block 520. At this point, the film 510 adheres to or becomes integrated with the plastic block 520 and hardens. The plastic block 520 is thus molded on the film 510.

[0073] A method of manufacturing the device module using the first and second dies 30, 40 will be described with reference to Fig. 8. The first step is to prepare the base 500 and the touch sensor 300 with the external connection 700 connected thereto. The touch sensor 300 and the embedded portion 710 of the external connection 700 are affixed onto the first face 521 of the plastic block 520 of the base 500 with the adhesive. As a result, the embedded portion 710 extends along the plastic block 520, from the touch sensor 300 to the end of the plastic block 520, and the lead-out portion 720 protrudes from the end of the plastic block 520.

[0074] The next step is to place the base 500 into the recess 41 of the second die 40. The recess 41 accordingly receives the touch sensor 300 and the embedded portion 710 of the external connection 700 that are fixed to the base 500. As a result, the end faces 524, 523 of the plastic block 520 extend flush with the first and second split faces 42, 43 of the second die 40 and opposed to the respective parts of the first and second split faces 33, 34 of the first die 30. At this point, the lead-out portion 720 of the external connection 700 is disposed between the end face 523 of the plastic block 520 and the second split face 34 of the first die 30 and between the second split faces 34, 43 of the first and second dies 30, 40.

[0075] After that, the first and second dies 30, 40 are brought close to each other to be closed together. Then, the projection 31 of the first die 30 is received in the recess 41 of the second die 40, and the first and second recesses 35, 36 communicate with the recess 41. The projection 31, the first and second recesses 35, 36, and the recess 41 define the cavity. The base 500, the touch sensor 300, and the embedded portion 710 of the external connection 700 are placed in the cavity. At this point, the end face 524 of the plastic block 520 of the base 500 is brought into contact with a part of the first split face 33 of the first die 30, and the first split face 33, 42 of the first and second dies 30, 40 are brought into contact with each other. The fixed portion 721 of the lead-out portion 720 of the external connection 700 is held between the end face 523 of the plastic block 520 of the base 500 and the second split face 34 of the first die 30, and the free portion 722 of the lead-out portion 720 is held between the second split face 34, 43 of the first and second dies 30, 40.

[0076] After that, plastic material R is injected through the sprue 32 of the first die 30 onto the base 500 in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 710 of the external connection 700 are embedded in the plastic material R on the base 500. This plastic material R hardens to form the plastic part 600. This is how to insert-mold the touch sensor 300 and the embedded portion 710 of the external connection 700 into the plastic part 600 on the base 500, with the lead-out portion 720 of the external connection 700 led out of the plastic part 600. After that, the first and second dies 30, 40 are separated from each other to take out the completed device module. Lastly, the fixed portion 721 is fixed to the outer face of the protruding portion 620 of the plastic part 600 with an adhesive.

[0077] The above described device module has at least the following technical features and advantages. First, the embedded portion 710 of the external connection 700 is embedded in the plastic part 600 and extends along the base 500 from the touch sensor 300 to the end face 523 of the base 500. The lead-out portion 720 of the external connection 700 is led out of the plastic part 600. Therefore, the insert-molding process can be performed placing the base 500, the touch sensor 300, and the embedded portion 710 of the external connection 700 in the cavity of the first and second dies 30, 40 while the lead-out portion 720 of the external connection 700 is held between the base 500 and the first die 30 and between the first and second dies 30, 40. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 720 of the external connection 700 into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 710 of the external connection 700 are affixed onto the base 500, and the lead-out portion 720 of the external connection 700 is held between the base 500 and the first die 30 and between the first and second dies 30, 40. This arrangement reduces the possibility of movement of the external connection 700 if pressed by the plastic material R injected into the cavity.

Fifth Embodiment

[0078] Next, a device module in accordance with the Fifth Embodiment of the invention will be described with reference to Fig. 9. The device module shown in Fig. 9 is a touch sensing device. The device module includes a base 500', a plastic part 600', a touch sensor 300 (device), and an external connection 700'. These constituents of the device module will be described below in detail. In Fig. 9, D1 refers to the thickness direction of the device module and the plastic part 600', and D2 refers to the lengthwise direction of the device module. D1 is orthogonal to D2. The short direction (not shown) of the device module is orthogonal to D1 and D2.

[0079] The base 500' is an insulating and translucent member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The base 500' is generally of U-shape in sectional view and includes a first face 501' and a second face 502' opposed to each other and first and second lengthwise end portions 503', 504'. The touch sensor 300 is fixed to the flat central area of the first face 501' of the base 500' and embedded in the plastic part 600'. The second face 502' of the base 500' has a flat central area serving as a touch sensing surface of the device module. The touch sensor 300 extends substantially parallel to the touch sensing surface. End faces of the first and second end portions 503', 504' faces upward (as shown in Fig. 9).

[0080] The plastic part 600' is an insulating member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic part 200 is generally of U-shape in sectional view and provided on the first face 501' of the base 500'. The plastic part 600' has lengthwise first and second end faces 601', 602'. The first and second end faces 601', 602' face upward. They are located at lower height position than the end faces of the end portions 503', 504' of the base 500'.

[0081] The external connection 700' is flexible. Specifically, the external connection 700' is a flexible printed board or a flexible and insulating transparent film. The external connection 700' includes an embedded portion 710' and a lead-out portion 720'. The embedded portion 710' of the external connection 700' is fixed to the first face 501' of the base 500' and embedded in the plastic part 600', and it includes a lengthwise first end of the external connection 700'. The first end of the external connection 700' is connected to the touch sensor 300 in a similar manner to the first end of the external connection 400 of the First Embodiment. The embedded portion 710' extends along the first face 501' of the base 500', from the touch sensor 300 to the second end face 602' of the plastic part 600'. The lead-out portion 720' is a portion excluding the embedded portion 710' of the external connection 700' and is led out of the second end face 602' of the plastic part 600'. The lead-out portion 720' includes a lengthwise second end of the external connection 700'.

[0082] The device module described above may be manufactured using first and second dies 30', 40' as illustrated in Fig. 10. The first die 30' includes a projection 31', a sprue 32', first and second split faces 33', 34', and a recess 35'. The projection 31' projects in the thickness direction D1 (downward in Fig. 10) toward the second die 40'. The sprue 32' passes through the first die 30' in the thickness direction D1. The first split face 33' is located on one side in the lengthwise direction D2 of the projection 31', and the second split face 34' is located on the other side in the lengthwise direction D2 of the projection 31'. The second split face 34' is located further to the other side of the thickness direction D1 (higher in Fig. 10) than the first split face 33' by the sum of the thickness of the lead-out portion 720' of the external connection 700' and the following distance. in the thickness direction D1 between the end face of the second end portion 504' of the base 500' and the second end face 602'. The recess 35' is provided between the projection 31' and the first split face 33' and extends to the other side in the thickness direction D1 (upward in Fig. 10). The recess 35' is of shape conforming to the outer shape of the first end portion 503' of the base 500'.

[0083] The second die 40' includes a recess 41' and first and second split faces 42', 43'. The recess 41' is adapted to receive the projection 31' and has a dimension in the thickness direction D1 (i.e. depth) larger than the dimension in the thickness direction D1 (i.e. height) of the projection 31' and substantially the same as the dimension in the thickness direction D1 of the base 500' excluding the first and second end portions 503', 504'. When the first and second dies 30', 40' are closed together, the recess 41' receives the projection 31' and communicates with the recess 35'. In this state, the projection 31', the recess 35', the recess 41', and the second end portion 504' of the base 500' define a space that serves as a cavity of the first and second dies 30', 40'. The cavity is of shape conforming to the outer shape of the device module excluding a distal portion of the lead-out portion 720' and the second end portion 504'. The first split face 42' is located on the one side in the lengthwise direction D2 of the recess 41', and the second split face 43' is located on the other side in the lengthwise direction D2 of the recess 41'. The first and second split faces 42', 43' extend at the same height position. When the first and second dies 30', 40' are closed together, the first split faces 33', 42' are in contact with each other, while a gap G" is left between the second split faces 34', 43'. The gap G" corresponds to the combined thickness in the thickness direction D1 of the lead-out portion 720' of the external connection 700' combined with the distance between the end face of the second end portion 504' of the base 500' and the second end face 602'.

[0084] A method of manufacturing the device module using the first and second dies 30', 40' will be described below with reference to Fig. 10. The first step is to prepare the base 500' and the touch sensor 300 with the external connection 700' connected thereto. The touch sensor 300 and the embedded portion 710' of the external connection 700' are affixed onto the first face 501' of the base 500' with an adhesive. As a result, the embedded portion 710' extends along the base 500'.

[0085] The next step is to place the base 500' into the recess 41' of the second die 40'. The first and second end portions 503', 504' of the base 500' protrude from the recess 41'. As a result, the first end portion 503' is opposed to the recess 35' of the first die 30', and the second end portion 504' is opposed to a part of the second split face 34' of the first die 30'. At this point, the basal portion of the lead-out portion 720' of the external connection 700' is disposed along the inner face of the second end portion 504' of the base 500', while the distal portion of the lead-out portion 720' is disposed between the second end portion 504' of the base 500' and the second split face 34 of the first die 30' and between the second split face 34', 43' of the first and second dies 30', 40'.

[0086] After that, the first and second dies 30', 40' are brought close to each other to be closed together. Then, the recess 41' of the second die 40' receives the projection 31' of the first die 30' and communicates with the recess 35'. Also, the first end portion 503' of the base 500' fits in the recess 35' of the first die 30', and the second end portion 504' is brought into contact via the lead-out portion 720' with a part of the second split face 34' of the first die 30'. The projection 31', the first recess 35', the recess 41', and the second end portion 504' define the cavity, and the base 500' excluding the second end portion 504', the touch sensor 300, and the embedded portion 710' of the external connection 700' are placed in the cavity. The first split faces 33', 42' of the first and second dies 30', 40' are in contact with each other. The basal portion of the lead-out portion 720' of the external connection 700' is held between the second end portion 504' of the base 500' and the first die 30'. The distal portion of the lead-out portion 720' is held between the second end portion 504' of the base 500' and the second split face 34' of the first die 30'.

[0087] After that, plastic material R is injected through the sprue 32' of the first die 30' onto the base 500'. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 710' of the external connection 700' are embedded in the plastic material R on the base 500'. This plastic material R hardens to form the plastic part 600'. This is how to insert-mold the touch sensor 300 and the embedded portion 710' of the external connection 700' in the plastic part 600' on the base 500', with the lead-out portion 720' of the external connection 700' led out of the plastic part 600'. Lastly, the first and second dies 30', 40' are separated from each other to take out the completed device module.

[0088] The above described device module has at least the following technical features and advantages. First, the embedded portion 710' of the external connection 700' is embedded in the plastic part 600' and extends along the base 500' from the touch sensor 300 to the second end face 602' of the plastic part 600'. The lead-out portion 720' of the external connection 700' is led out of the plastic part 600'. Therefore, the insert-molding process can be performed placing the base 500' excluding the second end portion 504', the touch sensor 300, the embedded portion 710' of the external connection 700' in the cavity of the first and second dies 30', 40' and holding the lead-out portion 720' of the external connection 700' between the second end portion 504' of the base 500' and the first die 30'. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 720' of the external connection 700' into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 710' of the external connection 700' are affixed onto the base 500', and the lead-out portion 720' of the external connection 700' is held between the base 500' and the first die 30'. This arrangement reduces the possibility of movement of the external connection 700' if pressed by the plastic material R injected into the cavity.

Sixth Embodiment

[0089] Next, a device module in accordance with the Sixth Embodiment of the invention will be described with reference to Fig. 11. The device module shown in Fig. 11 has the same configuration as that of the First Embodiment, except that a plastic part 800 and an external connection 900 are provided in place of the plastic part 200 and the external connection 400, respectively. These differences will be described below in detail, and overlapping descriptions will be omitted. Fig. 11 also indicates the directions D1 and D2.

[0090] The plastic part 800 is an insulating member of thermosoftening or thermosetting plastic material (e.g. polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or the like). The plastic part 800 includes a plastic body 810 and a protecting part 820. The plastic body 810 is generally U-shaped in sectional view. The plastic body 810 is provided on the first face 101 of the base 100. This causes the base 100 generally adhere to or be integrated with the plastic body 810 and harden (have lost flexibility) generally in a U-shaped curve extending along the plastic body 810. The touch sensor 300 is affixed onto the center area of the first face 101 of the base 100 and is embedded in the plastic body 810. The flat central area of the second face 102 of the base 100 serves as the touch sensing surface of the device module. The touch sensor 300 extends substantially parallel to the touch sensing surface. The protecting part 820 is a generally rectangular block contiguous with a lengthwise end of the plastic body 810 and extends in the lengthwise direction D2.

[0091] The external connection 900 is flexible. Specifically, the external connection 900 is a flexible printed board or a flexible and insulating transparent film. The external connection 900 includes an embedded portion 910 and a lead-out portion 920. The embedded portion 910 of the external connection 900 is fixed onto the first face 101 of the base 100 and embedded in the plastic body 810 of the plastic part 800, and it includes a lengthwise first end of the external connection 900. The first end of the external connection 900 is connected to the touch sensor 300 in a similar manner to the first end of the external connection 400 of the First Embodiment. The embedded portion 910 extends along the first face 101 of the base 100, from the touch sensor 300 to an end of the base 100.

[0092] The lead-out portion 920 is a portion excluding the embedded portion 910 of the external connection 900 and extends through and out of the protecting part 820. The lead-out portion 920 includes a fixed portion 921 and a free portion 922. The fixed portion 921 is contiguous with the embedded portion 910 and embedded in the protecting part 820. That is, the protecting part 820 covers the fixed portion 921 of the lead-out portion 920. The free portion 922 is contiguous with the fixed portion 921 and led out of the protecting part 820. The free portion 922 includes a lengthwise second end of the external connection 700.

[0093] The device module described above may be manufactured using first and second dies 50, 60 as illustrated Fig. 12. The first die 50 includes a projection 51, a sprue 52, first and second split faces 53, 54, and a recess 55. The projection 51 of the first die 50 projects in the thickness direction D1 (downward in Fig. 12). The sprue 52 passes through the first die 50 in the thickness direction D1. The first split face 53 is located on one side in the lengthwise direction D2 of the projection 51, and the second split face 54 is located on the other side in the lengthwise direction D2 of the projection 51. The second split face 54 is located further to the other side of the thickness direction D1 (higher in Fig. 12) than the first split face 53 by the thickness of the lead-out portion 920 of the external connection 900. The recess 55 is provided between the projection 51 and the second split face 54.

[0094] The second die 60 includes a recess 61, first and second split faces 62, 63, and a recess 64. The recess 61 is adapted to receive the projection 51 and has a dimension in the thickness direction D1 (i.e. depth) larger than the dimension in the thickness direction D1 (i.e. height) of the projection 51. When the first and second dies 50, 60 are closed together, the recess 61 receives the projection 51 and communicates with the recesses 55 and 64. The projection 51, the recess 55, the recess 61, and the recess 64 define a space that serves as a cavity of the first and second dies 50, 60. The cavity is of shape conforming to the outer shape of the device module excluding the free portion 922 of the lead-out portion 920. The cavity includes a space defined by the recess 55 and the recess 64, and this space conforms to the outer shape of the protecting part 820. The first split face 62 is located on the one side in the lengthwise direction D2 of the recess 61, and the second split face 63 is located on the other side in the lengthwise direction D2 of the recess 61. The first and second split faces 62, 63 extend at the same height position. When the first and second dies 50, 60 are closed together, the first split face 53, 62 are in contact with each other, while a gap G is left between the second split faces 54, 63 corresponding to the thickness of the lead-out portion 920.

[0095] A method of manufacturing the device module using the first and second dies 50, 60 will be described below with reference to Fig. 12. The first step is to prepare the base 100 and the touch sensor 300 with the external connection 900 connected thereto. The touch sensor 300 and the embedded portion 910 of the external connection 900 are affixed onto the first face 101 of the base 100 with an adhesive. As a result, the embedded portion 910 extends along the base 100 from the touch sensor 300 to the end of the base 100, and the lead-out portion 920 protrudes from the end of the base 100.

[0096] The next step is to place the base 100, the touch sensor 300 and the embedded portion 910 of the external connection 900 into the recess 61 of the second die 60. This causes the base 100 to curve generally in U-shape in sectional view conforming to the shape of the wall of the recess 61, and the embedded portion 910 is accordingly curved. In addition, the fixed portion 921 of the lead-out portion 920 of the external connection 900 is disposed between the recesses 55 and 64, and the free portion 922 is disposed between the second split faces 54, 63 of the first and second dies 50, 60.

[0097] After that, the first and second dies 50, 60 are brought close to each other to be closed together. Then, the recess 61 of the second die 60 receives the projection 51 of the first die 50 and communicates with the recesses 55, 64. Consequently, the projection 51, the recess 55, the recess 61, and the recess 64 define the cavity, the cavity, and the base 100, the touch sensor 300, and the embedded portion 910 of the external connection 900 are placed in the cavity. At this point, the first split faces 53, 62 of the first and second dies 50, 60 are in contact with each other. The free portion 922 of the lead-out portion 920 of the external connection 900 is held between the second split faces 54, 63 of the first and second dies 50, 60, and the fixed portion 921 is disposed in midair in the space defined by the recesses 55, 64 in the cavity.

[0098] After that, plastic material R is injected through the sprue 52 of the first die 50 onto the base 100 in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 910 of the external connection 900 are embedded in the plastic material R on the base 100, and the fixed portion 921 of the lead-out portion 920 is also embedded in the plastic material R. The plastic material R hardens to form the plastic part 800. At this point, the base 100 adheres to or becomes integrated with the plastic body 810 of the plastic part 800 and hardens. This is how to insert-mold the touch sensor 300 and the embedded portion 910 of the external connection 900 in the plastic body 810 of the plastic part 800 on the base 100, with the lead-out portion 920 of the external connection 900 passing through and out of the protecting part 820 of the plastic part 800. Lastly, the first and second dies 50, 60 are separated from each other to take out the completed device module.

[0099] The above described device module has at least the following technical features and advantages. First, the embedded portion 910 of the external connection 900 is embedded in the plastic part 800 and extends along the base 100 from the touch sensor 300 to the end of the base 100. The lead-out portion 920 of the external connection 900 passes through and is led out of the protecting part 820 of the plastic part 800. Therefore, the insert-molding process can be performed placing the base 100, the touch sensor 300, and the embedded portion 910 and the fixed portion 921 of the external connection 900 in the cavity of the first and second dies 50, 60 while the first and second dies 50, 60 hold therebetween the free portion 922 of the lead-out portion 920 of the external connection 900. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 920 of the external connection 900 into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 910 of the external connection 900 are affixed onto the base 100, and the lead-out portion 920 of the external connection 900 is held between the first and second dies 50, 60. This arrangement reduces the possibility of movement of the external connection 900 if pressed by the plastic material R injected into the cavity. Further advantageously, the fixed portion 921 of the lead-out portion 920 is embedded in the protecting part 820, improving the tensile strength of the lead-out portion 920.

Seventh Embodiment

[0100] Next, a device module in accordance with the Seventh Embodiment of the invention will be described with reference to Fig. 13. The device module in Fig. 13 has the same configuration as that of the Sixth Embodiment except for the following two differences. The first difference is that a plastic part 800' and an external connection 900' are provided in place of the plastic part 800 and the external connection 900. The second difference is that the device module further includes a protecting part 1000. The differences will be described below in detail, and descriptions overlapping with the Sixth Embodiment will be omitted.

[0101] The plastic part 800' has substantially the same configuration as that of the plastic part 800. The difference is that the plastic part 800' includes a projection 820' in place of the protecting part 820. The projection 820' is contiguous with a lengthwise end of the plastic body 810' and extends upward. The protecting part 1000 is a rectangular insulating plastic block affixed to the projection 820'.

[0102] The external connection 900' has substantially the same configuration as that of the external connection 900, except that it includes a lead-out portion 920' passing through and out of the protecting part 1000. In other words, the protecting part 1000 covers the fixed portion 921' of the lead-out portion 920'. The fixed portion 921' of the lead-out portion 920' is contiguous with the embedded portion 910' and is embedded in the protecting part 1000. The free portion 922' of the lead-out portion 920' is contiguous with the fixed portion 921' and led out of the protecting part 1000.

[0103] The device module described above may be manufactured using first and second dies 70, 80 as illustrated Fig. 14. The first die 70 has substantially the same configuration as that of the first die 10, except for the height of a second split face 74. More particularly, the second split face 74 is located further to the other side of the thickness direction D1 (higher in Fig. 14) than the first split face 73 by the thickness of the protecting part 1000. The second die 80 has the same configuration as the second die 20. When the first and second dies 70, 80 are closed together, the first split face 73, 82 are in contact with each other, while a gap G'" is left between the second split faces 74, 83. The gap G'" corresponds to the thickness of the protecting part 1000. The cavity of the first and second dies 70, 80 is of shape conforming to the outer shape of the device module excluding the protecting part 1000 and the lead-out portion 920'.

[0104] The fixed portion 921' of the lead-out portion 920' of the external connection 900' may be embedded in the protecting part 1000 in the following method using dies (not shown). First, the external connection 900' is prepared. The external connection 900' may or may not be connected to the touch sensor 300. The fixed portion 921' of the lead-out portion 920' of the external connection 900' is placed in the cavity of the dies, and plastic material is injected into the cavity. As a result, the fixed portion 921' of the lead-out portion 920' of the external connection 900' is embedded (insert-molded) in the plastic material. The hardened plastic material forms the protecting part 1000. This is how to provide the protecting part 1000' in such a manner as to partially cover the lead-out portion 920'.

[0105] A method of manufacturing the device module using the first and second dies 70, 80 will be described below with reference to Fig. 14. The first step is to prepare the base 100 and the touch sensor 300 with the external connection 900' connected thereto. Also prepared is the protecting part 1000 provided on the lead-out portion 920' of the external connection 900'. The touch sensor 300 and the embedded portion 910' of the external connection 900' are fixed onto the first face 101 of the base 100 with an adhesive. As a result, the embedded portion 910' extends along the base 100 from the touch sensor 300 to the end of the base 100, and the lead-out portion 920' protrudes from the end of the base 100. The protecting part 1000 is disposed near the end of the base 100.

[0106] The next step is to place the base 100, the touch sensor 300, and the embedded portion 910' of the external connection 900' into the recess 81 of the second die 80. This causes the base 100 to curve generally in U-shape in sectional view conforming to the shape of the wall of the recess 81, and the embedded portion 910' is accordingly curved. In addition, the protecting part 1000 is disposed between the second split face 74, 83 of the first and second dies 70, 80.

[0107] After that, the first and second dies 70, 80 are brought close to each other to be closed together. Then, the projection 71 of the first die 70 is received in the recess 81 of the second die 80. Consequently, the projection 71 and the recess 81 form the cavity, and the base 100, the touch sensor 300, and the embedded portion 910' of the external connection 900' are placed in the cavity. At this point, the first split faces 73, 82 of the first and second dies 70, 80 are in contact with each other. The protecting part 1000 is held between the second split faces 74, 83 of the first and second dies 70, 80, and a part of the protecting part 1000 (the left end in Fig. 14) is disposed in the cavity.

[0108] After that, plastic material R is injected through the sprue 72 of the first die 70 onto the base 100 in the cavity. The cavity is filled with the plastic material R, so that the touch sensor 300 and the embedded portion 910' of the external connection 900' are embedded in the plastic material R on the base 100, and the plastic material R adheres to the above-mentioned part of the protecting part 1000. The plastic material R hardens to form the plastic part 800'. At this point, the base 100 adheres to or becomes integrated with the plastic body 810' of the plastic part 800' and hardens. This is how to insert-mold the touch sensor 300 and the embedded portion 910' of the external connection 900' in the plastic body 810' of the plastic part 800' on the base 100. Also, the projection 820' of the plastic part 800' is fixedly attached to the protecting part 1000, and the lead-out portion 920' of the external connection 900' passes through and out of the protecting part 1000. Lastly, the first and second dies 70, 80 are separated from each other to take out the completed device module.

[0109] The above described device module has at least the following technical features and advantages. First, the embedded portion 910' of the external connection 900' is embedded in the plastic part 800' and extends along the base 100 from the touch sensor 300 to the base 100. The lead-out portion 920' of the external connection 900' passes through and is led out of the protecting part 1000 fixed to the plastic part 800'. Therefore, the insert-molding process can be performed placing the base 100, the touch sensor 300 and the embedded portion 910' of the external connection 900' in the cavity of the first and second dies 70, 80 while the first and second dies 70, 80 hold the protecting part 1000 therebetween. This arrangement makes it possible to manufacture the device module without inserting the lead-out portion 920' of the external connection 900' into a housing recess of a die. Moreover, the touch sensor 300 and the embedded portion 910' of the external connection 900' are fixed onto the base 100, the first and second dies 70, 80 hold therebetween the protecting part 1000, and the lead-out portion 920' of the external connection 900' passes through and out of the protecting part 1000. This arrangement reduces the possibility of movement of the external connection 900' if pressed by the plastic material R injected into the cavity. Further advantageously, the protecting part 1000 is held between the first and second dies 70, 80, making it possible to protect the lead-out portion 920' of the external connection 900' against the first and second dies 70, 80. Further, the fixed portion 921' of the lead-out portion 920' is embedded in the protecting part 1000 and the protecting part 1000 is fixed to the plastic part 800', improving the tensile strength of the lead-out portion 920'.

[0110] The device module of the invention is not limited to the embodiments as described above and may be modified in any manner within the scope of Clauses. Specific modifications will be described with reference to Fig. 15 to Fig. 21.

[0111] In the First to the Third Embodiments and the Sixth to the Seventh Embodiments, the base is a transparent film. In the Fourth Embodiment, the base includes a film and a plastic block. In the Fifth Embodiment, the base is made of thermosoftening or thermosetting plastic material. However, the base of the invention may be modified in any manner as long as the base has a face provided with the plastic part, a device (to be described) is provided on the face, and the embedded portion of the external connection extends along the face. For example, the base of any of the First to Third, Sixth and Seventh Embodiments may be replaced with the base of the Fourth or Fifth Embodiment. Conversely, the base of the Fourth or Fifth Embodiment may be replaced with the base of any of the First to Third, Sixth and Seventh Embodiments. Any of these bases may be a film or plastic block with a hard coat, an adhesive layer, an anti-reflection layer, and/or a polarizing plate.

[0112] The base may be U-shaped in sectional view as in the First to Third, Sixth and Seventh Embodiments, but it is not limited to this. For example, the base may be of flat shape like a base 100"' shown in Fig. 15 and Fig. 16. The base may also be configured like a base 100"" shown in Fig. 17, including a flat horizontal portion and a pair of vertical portions contiguous with the ends of the horizontal portion and bent at right angles to the horizontal portion. The base of the First to Third, Sixth and Seventh Embodiments may be modified to be arc-shaped. The base of the Fourth and Fifth Embodiments may be also modified to be of flat shape, of shape including a horizontal portion and vertical portions, or be arc-shaped. Further, the base may be formed of a film that does not harden (does not lose flexibility) after the formation of the plastic material. The base may be provided with ornamental printing as in the above embodiments, or it may be provided without ornamental printing. The base may be made of an opaque material.

[0113] Translucent material is used for the plastic block of the Fourth Embodiment and the base of the Fifth Embodiment. However, a plastic material with no translucency may be used.

[0114] The external connection of the invention may be modified in any manner as long as it is connected to a device (to be described) and includes an embedded portion, which extends along the base and is embedded in the plastic part, and a lead-out portion, which is contiguous with the embedded portion and led out of the plastic part. The lead-out portion may be led out of a portion other than the end face of the plastic part. For example, Fig. 19 shows a modified lead-out portion 420' that is not fixed to the outer face of the protruding portion 220' of the plastic part 200' but led out of a curved face of the protruding portion 220'.

[0115] The external connection may be a flexible printed board or a flexible and insulating transparent film as in the First to the Seventh Embodiments and the modifications described above. However, the external connection is not limited to these. For example, the external connection may be a lead wire, a header pin, or a rigid board. The external connection may include a film and a conductive line. In this case, the film may be contiguous with the base of any of the First to Third, Sixth and Seventh Embodiments, and the conductive line may be printed on the base and the film. The conductive line on the base may serve as an embedded portion, and the film and the conductive line on the film may serve as a lead-out portion.

[0116] The plastic material may be an insulating thermosoftening or thermosetting plastic material as in the First to the Seventh Embodiments. However, the plastic material of the invention may be any insulating plastic material that can be provided on the base and adapted to embed therein a device (a sensor, an electronic device, or a circuit board) and an embedded portion of an external connection. The plastic material may be of U-shape in sectional view or any other shape. For example, the plastic part may have a flat shape, like the plastic part 200" shown in Fig. 15 to Fig. 17, or an arc shape.

[0117] The protecting part 820 of the Sixth Embodiment is a plastic block contiguous with an end of the plastic body 810, and the lead-out portion 920 passes through and out of the protecting part 820. The protecting part 1000 of the Seventh Embodiment is a plastic block, and the lead-out portion 920' passes through and out of the protecting part 1000. However, the protecting part may be modified in any manner as long as it partially covers the lead-out portion. The protecting part may be made of any other material that allows the lead-out portion of the external connection to pass therethrough, i.e. any plastic material such as an elastomer, metal, or ceramic. The protecting part may have a through hole for passing the lead-out portion therethrough, thereby letting the lead-out portion pass through the protecting part. The protecting part may be a film, a film coating, or an adhesive provided on the fixed portion of the lead-out portion. The protecting part may include a plurality of pieces that can be fixed to the fixed portion of the lead-out portion surrounding the fixed portion. The protecting part may cover only one face of the fixed portion of the lead-out portion.

[0118] The protecting part may be a film configured like a protecting part 1000' shown in Fig. 20. This modified protecting part 1000' is a plastic film or a copper foil that is stuck or applied to the fixed portion of the lead-out portion 920' so as to cover the fixed portion of the lead-out portion 920' of the external connection 900'. In this case, the first and second dies 70, 80 may be modified to provide such a distance between the second split faces 74, 83 as to hold the protecting part 1000' between the second split faces 74, 83 when the first and second dies 70, 80 are closed together.

[0119] The protecting part 1000 of the Seventh Embodiment is fixed to the projection 820' of the plastic part 800' at its left end as shown in Fig. 13. However, the protecting part of the invention may be fixed to the plastic part in any manner. For example, Fig. 21 illustrates a modified protecting part 1000 having a part embedded in a projection 820" of a plastic part 800" such that the outer circumference of the protecting part 1000 is surrounded by the projection 820". In this case, the first and second dies 70, 80 may be modified to provide a cavity of shape conforming to the shape of the projection 820".

[0120] The device of the device module may be a touch sensor used as a capacitive touch panel as in the First to Seventh Embodiments and the modifications described above. However, the device of the invention may be any type of sensor, any type of electronic component, or any type of circuit board. The sensor may be of any type including a touch panel of type other than the capacitive type (for example, a touch panel of resistive film-type, optical-type, ultrasonic-type, or in-cell type), a touch switch (for example, a touch switch of capacitive, resistive film-type, optical-type, ultrasonic-type, or in-cell type), or a sensor other than the touch panel and the touch switch (for example, a magnetic sensor, an optical sensor, or a light-dark sensor) can be used. In the touch panel and the touch switch (touch sensor), the electrode may be provided on the base by any well-known printing method. The touch panel and the touch switch may be opaque. The touch sensing surface of the touch panel or the touch switch is not limited to the second surface of the base. For example, the touch sensing surface may be an outer surface of a panel provided on the side of the outer surface of the base. Also, an electronic component or a circuit board in place of a sensor may be embedded in the plastic part. Examples of the electronic component include active components (for example, semiconductor) and passive components (for example, a resistor, a capacitor, and a coil).

[0121] The touch sensor may be fixed directly onto the base as in the First to Seventh Embodiments. The device may be indirectly provided on the base via a spacer or the like.

[0122] The device module may be a touch sensing device as in the First to Seventh Embodiments and the modifications described above. The device module may be modified to a window part of a panel P of a touch sensing device as shown in Fig. 18.

[0123] The device module manufacturing methods of the First to Seventh Embodiments may be modified such that the touch sensor 300 is replaced with a device described above. In the device module manufacturing methods of the First to the Seventh Embodiment, the touch sensor and the embedded portion of the external connection are affixed onto the base. However, the manufacturing methods of the invention may be modified such that only the device is affixed onto the base. In this case, the embedded portion may be merely placed on the base. In the device module manufacturing methods of the First to Third Embodiments, the lead-out portion of the external connection is held entirely between the first and second dies. However, the manufacturing methods of the invention are not limited to this and may be modified as follows. For example, the lead-out portion may be held between the base and the first die and between the first and second dies as in the Fourth Embodiment. Alternatively, the lead-out portion may be held between the base and the first die as in the Fifth Embodiment. Further alternatively, a part of the lead-out portion may be placed in the cavity while the remaining portion thereof may be held between the first and second dies as in the Sixth Embodiment. Still alternatively, the lead-out portion may not be held between the base and the first die and/or between the first and second dies. Instead, the lead-out portion may be provided with a protecting part for partially covering the lead-out portion, and the protecting part may be held between the base and the first die and/or between the first and second dies. The manufacturing methods can also be modified such that the protecting part is not placed in the cavity or that the protecting part is not fixed to the plastic material injected into the cavity.

[0124] In the device module manufacturing methods of the First to the Seventh Embodiments, the embedded portion of the external connection connected to the touch sensor is fixed on the base. However, the manufacturing methods can be modified such that the device is fixed to the base before the embedded portion of the external connection is connected to the device and fixed or mounted on the base.

[0125] The cavity of the first and second dies may be of any shape if conforming to the outer shape of the device module excluding at least a part of the lead-out portion, excluding a part of the plastic part and the lead-out portion, or excluding the protecting part and the lead-out portion. For example, the first and second dies may be modified to have recesses that forms a cavity when where the first and second dies are closed together. Alternatively, a projection provided on the second die may be inserted into a recess provided in the first die, and the projection and the recess form a cavity. The sprue may be provided in at least one of the first and second dies.

[0126] In the First to the Seventh Embodiments, the second split face of the first die is located higher than the first split face of the first die to form the gap G, G', G", or G". However, the gap G, G', G" or G" may be formed by locating the second split face of the second die lower than the first split face of the second die. Alternatively, the gap G, G', G", or G" may be formed by locating the second split face of the first die higher than the first split face of the first die and locating the second split face of the second die lower than the first split face of the second die.

[0127] It should be appreciated that the above-described embodiments and modifications are described by way of examples only. The materials, shapes, dimensions, numbers, arrangements, and other configurations of the device module and the first and second dies may be modified as long as they provide the same functions.

Reference Signs List

First Embodiment

[0128] 

10: first die

20: second die

R: plastic material

100: base

101: first face

102: second face

200: plastic part

300: touch sensor (device)

400: external connection

410: embedded portion

420: lead-out portion

Second Embodiment

[0129] 

10': first die

20: second die

R: plastic material

100': base

101': first face

102': second face

110': base body

120': affixed portion

200: plastic material

300: touch sensor (device)

400: external connection

410: embedded portion

420: lead-out portion

Third Embodiment

[0130] 

10: first die

20': second die

R: plastic material

100": base

101": first face

102": second face

200': plastic part

210': plastic body

220': protruding portion

230': protruding portion

300: touch sensor (device)

400': external connection

410': embedded portion

420': lead-out portion

421': fixed portion

422': free portion

Fourth Embodiment

[0131] 

30: first die

40: second die

R: plastic material

500: base

510: film

520: block

600: plastic part

610: plastic body

620: protruding portion

630: protruding portion

300: touch sensor (device)

700: external connection

710: embedded portion

720: lead-out portion

721: fixed portion

722: free portion

Fifth Embodiment

[0132] 

30': first die

40': second die

R: plastic material

500': base

600': plastic part

300: touch sensor (device)

700': external connection

710': embedded portion

720': lead-out portion

Sixth Embodiment

[0133] 

50: first die

60: second die

R: plastic material

100: base

800: plastic part

810: plastic body

820: protecting part

300: touch sensor (device)

900: external connection

910: embedded portion

920: lead-out portion

921: fixed portion

922: free portion

Seventh Embodiment

[0134] 

70: first die

80: second die

R: plastic material

100: base

800': plastic part

810': plastic body

820': projection

300: touch sensor (device)

900': external connection

910': embedded portion

920': lead-out portion

921': fixed portion

922': free portion

1000: protecting part

[0135] The description includes the following clauses concerning embodiments of the invention:

Clause 1
A device module comprising:

a base (100, 100', 100", 100"', 100"", 500, 500');

a plastic part (200', 200', 200", 600, 600', 800', 800', 800") provided on the base;

a device (300) provided on the base and embedded in the plastic part, the device being a sensor, an electronic device, or a circuit board; and

an external connection (400, 400', 700, 700', 900, 900'), the external connection including:

an embedded portion (410, 410', 710, 710', 910, 910') being connected to the device, extending along the base, and being embedded in the plastic part, and

a lead-out portion (420, 420', 720, 720', 920, 920') being contiguous with the embedded portion and led out of the plastic part.

Clause 2 The device module according to Clause 1, wherein
the base (100') includes a base body (110') and an affixed portion (120'), the base body being fixed to the plastic part (200), and the affixed portion being contiguous with the base body and not fixed to the plastic part, and
the lead-out portion (420) is affixed to and extends along the affixed portion.

Clause 3 The device module according to Clause 1, wherein
the plastic part (200') includes a plastic body (210') and a protruding portion (220') contiguous with the plastic body, the plastic body being affixed to the base (100"), and
the lead-out portion (420') includes a fixed portion (421') and a free portion (422') contiguous with the fixed portion, the fixed portion being affixed to and extending along the protruding portion.

Clause 4 The device module according to Clause 1, further comprising a protecting part (820, 1000, 1000') configured to partially cover the lead-out portion (920, 920').

Clause 5 The device module according to Clause 4, wherein
the protecting part (820, 1000, 1000') is contiguous with or affixed to the plastic part (800, 800', 800").

Clause 6
The device module according to Clause 1, wherein
the lead-out portion (420, 720) is partially affixed to an outer face of the plastic part (600, 200').

Clause 7 The device module according to any of Clauses 1 to 6, wherein
the sensor (300) is a film sensor, and
the external connection (400, 400', 700, 700', 900, 900') is of film shape to be provided integrally with the sensor.

Clause 8 A method of manufacturing a device module, the method comprising:

preparing a device (300), an external connection (400, 400', 700, 700'), and a base (100, 100', 100", 100"', 100"", 500, 500'), the device being a sensor, an electronic device, or a circuit board, the external connection including a lead-out portion (420, 420', 720, 720') and an embedded portion (410, 410', 710, 710'), and the embedded portion being connected to the device;

affixing the device and the embedded portion of the external connection onto the base;

followed by placing the base, the device, and the embedded portion of the external connection in a cavity of first (10, 10', 30, 30') and second (20, 20', 40, 40') dies, and holding the lead-out portion of the external connection between the first and second dies or between the first die and the base; and

in this state, injecting a plastic material (R) onto the base in the cavity to insert-mold the device and the embedded portion of the external connection in the plastic material.

Clause 9 The device module manufacturing method according to Clause 8, wherein
the affixing of the embedded portion (410) includes affixing the embedded portion in such a manner as to extend from the device (300) on the base (100, 100"') to an end of the base.

Clause 10
The device module manufacturing method according to Clause 8, wherein
the base (100') includes a base body (110') and an affixed portion (120'), the affixed portion being contiguous with the base body,
the affixing onto the base includes affixing the device (300) and the embedded portion (410) of the external connection (400) onto the base body of the base and affixing the lead-out portion (420) of the external connection onto the affixed portion of the base,
the placing in the cavity includes placing the base body of the base, the device, and the embedded portion of the external connection in the cavity,
the holding between the first (10') and second (20) dies includes holding the lead-out portion of the external connection and the affixed portion of the base between the first and second dies, and
the injection of the plastic material (R) includes injecting the plastic material onto the base body of the base and thereby insert molding the device and the embedded portion of the external connection in the plastic material.

Clause 11
The device module manufacturing method according to Clause 8, wherein
the lead-out portion (420') includes a fixed portion (421') contiguous with the embedded portion (410') and a free portion (422') contiguous with the fixed portion,
the placing in the cavity includes disposing the fixed portion of the lead-out portion along a wall of the cavity,
the holding between the first (10) and second (20')dies includes holding the free portion of the lead-out portion between the first and second dies, and
the injection of the plastic material (R) includes injecting the plastic material onto the base (100") in the cavity to insert-mold the device (300), the embedded portion of the external connection, and the fixed portion of the lead-out portion of the external connection in the plastic material.

Clause 12 The device module manufacturing method according to Clause 8, wherein
the lead-out portion (920) includes a fixed portion (921) contiguous with the embedded portion (910) and a free portion (922) contiguous with the fixed portion,
the placing in the cavity includes disposing the fixed portion of the lead-out portion in midair in the cavity,
the holding between the first (50) and second (60) dies includes holding the free portion of the lead-out portion between the first and second dies, and
the injection (R) of the plastic material includes injecting the plastic material onto the base (100) in the cavity to insert-mold the device (300), the embedded portion of the external connection, and the fixed portion of the lead-out portion of the external connection in the plastic material.

Clause 13 The device module manufacturing method according to Clause 8, wherein
the holding of the lead-out portion (720) of the external connection (700) between the first (30) and second (40) dies includes holding the lead-out portion also between the first die and the base (500).

Clause 14 A method of manufacturing a device module, the method comprising:

preparing an external connection (900'), a device (300), a protecting part (1000, 1000'), and a base (100), the external connection including an embedded portion (910') and a lead-out portion (920'), and the device being a sensor, an electronic device, or a circuit board and connected to the embedded portion, and the protecting part partially covering the lead-out portion;

affixing the device and the embedded portion of the external connection onto the base;

placing the base, the device, and the embedded portion of the external connection into a cavity of first (70) and second (80) dies, and holding the protecting part between the first and second dies or between the first die and the base; and

in this state, injecting a plastic material (R) onto the base in the cavity to insert-mold the device and the embedded portion of the external connection in the plastic material.

Clause 15 The device module manufacturing method according to Clause 14, wherein
the holding of the protecting part (1000, 1000') includes disposing a part of the protecting part in the cavity, and
the injection of the plastic material (R) includes affixing the part of the protecting part to the plastic material injected in the cavity.

Claims

1. A method of manufacturing a device module, the method comprising:

preparing:

a. a device (300) comprising a sensor, an electronic device, or a circuit board,

b. a flexible external connection (400) including a lead-out portion (420) and an embedded portion (410), the embedded portion being connected to the device, and

c. a base (100') being formed of a film of plastics material and including a base body (110') and an affixed portion (120') contiguous with the base body;

characterised by the steps of:

fixing the device to the base body with an adhesive;

fixing the embedded portion of the flexible external connection to the base body with an adhesive such that the embedded portion extends along the base body from the device to the affixed portion;

fixing the lead-out portion of the external connection onto the affixed portion of the base with an adhesive;

placing the base body, the device, and the embedded portion of the external connection in a second die (20);

placing the affixed portion of the base and the lead-out portion of the external connection between a split face (14') of a first die (10') and a split face (23) of the second die;

closing the first and second dies so as to

i. place the base body, the device, and the embedded portion of the flexible external connection in a cavity of the first and second dies and

ii. hold the affixed portion of the base and the lead-out portion of the flexible external connection in a gap (G) between the split faces of the first and second dies or between the split face of the first die and the base; and

injecting a plastic material (R) onto the base body in the cavity to insert-mould the device and the embedded portion of the flexible external connection in the plastic material.

2. A method of manufacturing a device module, the method comprising:

preparing:

a. a device (300) comprising a sensor, an electronic device, or a circuit board;

b. a flexible external connection (400') including a lead-out portion (420') and an embedded portion (410'), the embedded portion being connected to the device, the lead-out portion including a fixed portion (421') contiguous with the embedded portion and a free portion (422') contiguous with the fixed portion; and

c. a base (100) formed of a film of plastics material;

characterised by the steps of:

fixing the device onto the base with an adhesive;

fixing the embedded portion of the flexible external connection onto the base with an adhesive such that the embedded portion extends along the base from the device to an end of the base, and protruding the lead-out portion from the end of the base;

placing the base, the device, and the embedded portion of the flexible external connection in a second die (20'), disposing the fixed portion of the lead-out portion along a wall of the cavity of a first (10) and the second dies, and placing the free portion of the lead-out portion of the flexible external connection between a split face (14) of the first die and a split face (23') of the second die;

closing the first and second dies so as:

i. to place the base, the device, and the embedded portion of the flexible external connection in the cavity of the first and second dies and

ii. to hold the free portion of the lead-out portion in a gap (G) between the split faces of the first and second dies, and

injecting a plastic material (R) onto the base in the cavity to insert-mold the device, and the embedded portion of the flexible external connection in the plastic material, and bringing the fixed portion of the lead-out portion of the flexible external connection into intimate contact with the plastic material.

3. A method of manufacturing a device module, the method comprising:

preparing

a. a device (300) comprising a sensor, an electronic device, or a circuit board,

b. a flexible external connection (900) including a lead-out portion (920) and an embedded portion (910), the embedded portion being connected to the device, the lead-out portion including a fixed portion (921) contiguous with the embedded portion (910) and a free portion (922) contiguous with the fixed portion, and

c. a base (100) formed of a film of plastics material;

characterised by the steps of:

fixing the device onto the base with an adhesive,

fixing the embedded portion of the flexible external connection onto the base with an adhesive such that the embedded portion extends along the base from the device to an end of the base, and protruding the lead-out portion from the end of the base;

placing the base, the device, and the embedded portion of the flexible external connection in a second die (60), and placing the free portion of the lead-out portion of the flexible external connection between a split face (54) of a first die (50) and a split face (63) of the second die;

closing the first and second dies so as

i. to place the base, the device, and the embedded portion of the external connection in a cavity of the first and second dies,

ii. to dispose the fixed portion of the lead-out portion in midair in the cavity, and

iii. to hold the free portion of the lead-out portion in a gap (G) between the split faces of the first and second dies, and

injecting a plastic material (R) onto the base in the cavity to insert-mold the device, the embedded portion of the flexible external connection, and the fixed portion of the lead-out portion of the flexible external connection in the plastic material.

4. A method of manufacturing a device module, the method comprising:

a. preparing a device (300) comprising a sensor, an electronic device, or a circuit board,

b. preparing a flexible external connection (900') including an embedded portion (910') connected to the device and a lead-out portion (920'),

c. preparing a base (100) formed of a film of plastics material, and characterised by the steps of:

d. preparing a protecting part (1000, 1000') partially covering the lead-out portion

fixing the device onto the base with an adhesive
fixing the lead-out portion of the flexible external connection onto the base with an adhesive such that the embedded portion extends along the base from the device to an end of the base;
placing the base, the device, and the embedded portion of the flexible external connection in a second die (80), and placing the protecting part between a split face (74) of a first die (70) and a split face (83) of the second die;
closing the first and second dies so as

i. to place the base, the device, and the embedded portion of the flexible external connection into a cavity of first and second dies, and

ii. to hold the protecting part between the split faces of the first and second dies; and

injecting a plastic material (R) onto the base in the cavity to insert-mold the device and the embedded portion of the flexible external connection in the plastic material.

5. The method according to claim 4, wherein
the protecting part (1000, 1000') is held such that a part of the protecting part is within the cavity, and
the injection of the plastic material (R) includes fixing the part of the protecting part within the cavity to the plastic material injected in the cavity.

6. The method according to any one of the preceding claims, wherein the device (300) is a touch panel or a touch switch.

7. A device module comprising:

a base (100') being formed of a film of plastics material and including a base body (110') and an affixed portion (120') contiguous with the base body;

a plastic part (200') being fixed to the base body but not fixed to the affixed portion;

a device (300) fixed on the base body with an adhesive and insert-moulded in the plastic part, the device being a sensor, an electronic device, or a circuit board; and

a flexible external connection (400) including:

an embedded portion (410) being connected to the device, and insert-moulded in the plastic part, and

a lead-out portion (420) being contiguous with the embedded portion and led out of the plastic part,

characterised in that

the embedded portion (410) of the flexible external connection (400) is fixed on the base body with an adhesive and extends along the base body from the device (300) to the boundary between the base body (110') and the affixed portion (120'), and

the lead-out portion (420) of the flexible external connection (400) is fixed to the affixed portion (120') with an adhesive and extends along the affixed portion (120').

8. A device module comprising:

a base (100") formed of a film of plastics material;

a plastic part (200') fixed to the base;

a device (300) fixed on the base with an adhesive and insert-moulded in the plastic part, the device being a sensor, an electronic device, or a circuit board; and

a flexible external connection (400'),

characterised in that

the plastic part (200') includes a plastic body (210') and a protruding portion (220') contiguous with the plastic body, the plastic body being fixed to the base (100") but the protruding portion not being fixed to the base,

the flexible external connection includes:

a. an embedded portion (410') which is connected to the device (300), is fixed to the base with an adhesive, extends along the base from the device (300) to an end of the base, and is insert-moulded in the plastic part (200'), and

b. a lead-out portion (420') which is contiguous with the embedded portion and extends out of the plastic part, and

the lead-out portion (420') includes:

c. a fixed portion (421') which is contiguous with the embedded portion, is fixed to an outer face of the protruding portion, and extending along the protruding portion, and

d. a free portion (422') contiguous with the fixed portion and protruding from an end face of the protruding portion.

9. A device module, comprising:

a base (100) formed of a film of plastics material;

a plastic part (800, 800', 800") fixed to the base;

a device (300) fixed on the base with an adhesive and insert-moulded in the plastic part, the device being a sensor, an electronic device, or a circuit board; and

a flexible external connection (900, 900'),

characterised in that

the flexible external connection includes:

an embedded portion (910, 910') which is connected to the device, is fixed to the base with an adhesive, extends along the base from the device to an end of the base, and is insert-moulded in the plastic part, and

a lead-out portion (920, 920') which is contiguous with the embedded portion and extends out of the plastic part, and

the device module further comprises a protecting part (820, 1000, 1000') which is contiguous with or fixed to the plastic part (800, 800', 800") so as configured to partially cover the lead-out portion (920, 920').

10. The device module according to claim 9, wherein
the protecting part (820, 1000, 1000') is formed from plastics material.

11. The device module according to any one of claims 7 to 10, wherein
the base includes:

a first face being an inner face of the base and provided with the plastic part, and

a second face being an outer face of the base and serving as a touch sensing surface adapted to be touched by a detection object, and

the device is a touch sensor.

12. The device module according to any one of claims 7 to 11, wherein
the device (300) is a film sensor, and
the external connection (400, 400', 700, 700', 900, 900') is of film shape to be provided integrally with the sensor.

13. The device module according to any one of claims 7 to 10, wherein the device (300) is a touch panel or a touch switch.

Drawing